Method for manufacturing a planar resistance heating element

• US 7,520,049 B2
• Filed: 11/22/2005
• Issued: 04/21/2009
• Est. Priority Date: 07/06/2005
• Status: Active Grant

• Current Assignee: Suntech Co., Ltd. (Orient Precision Industries, Inc.)
• Original Assignee: Suntech Co., Ltd. (Orient Precision Industries, Inc.)
• Inventors: Kim, Gyongtae
• Primary Examiner(s): Phan; Thiem
• Application Number:
  US11/283,798
• Publication Number:
  US 20070007269A1
• Time in Patent Office: 1,246 Days
• Field of Search: 296/21, 296/101, 296/11, 296/20, 298/25, 298/29, 298/46, 298/47, 205/98, 205/201, 219/219, 219/260, 219/505, 438/612, 438/652
• US Class Current: 29/621
• CPC Class Codes: C22C 1/11 Making amorphous alloys
• CPC Class Codes: C22F 1/04 of aluminium or alloys based thereon
• CPC Class Codes: C23C 18/10 Deposition of aluminium only
• CPC Class Codes: C23F 17/00 Multi-step processes for surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by subclass C21D or C22F or class C25 coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups C23C2/00 - C23C26/00, or by combinations of methods providedfor in subclasses C23C and C25D, C23C28/00
• CPC Class Codes: H05B 3/845 specially adapted for reflecting surfaces, e.g. bathroom - or rearview mirrors
• CPC Class Codes: Y10T 29/49082 Resistor making
• CPC Class Codes: Y10T 29/49083 Heater type
• CPC Class Codes: Y10T 29/49099 Coating resistive material on a base
• CPC Class Codes: Y10T 29/49101 Applying terminal
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49124 On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49156 with selective destruction of conductive paths

Abstract

Disclosed herein is a manufacturing method of a planar resistance heating element and a planar resistance heating element made using the method. In the manufacturing method of a planar resistance heating element by etching an aluminum foil deposited on an insulating substrate in a desired pattern, printing carbon paste and connecting current input terminals in parallel, the aluminum foil is adapted to undergo a multiple step tempering process to thereby prevent heat deformation. The carbon paste acting as a resistor element is made of electrically conductive carbon, graphite, a resin, a solvent and a hardener which are mixed so as to optimize physical properties of the carbon paste. As a result, prevention of heat deformation of the insulating substrate, uniform heat conductivity, excellent heat-generation effect and easy manufacture may be achieved. In addition, the use of the carbon paste having optimized physical properties as a resistor element results in good heat-generation and near-zero temperature variation.

Claims

1. A method for manufacturing a planar resistance heating element, said method comprising:

a) tempering an aluminum foil deposited on an insulating substrate in a stepwise manner at a temperature of 0 to 40 degree C. for 1.5 to 2.5 hours, thereafter at a temperature of 40 to 70 degree C. for 1.5 to 2.5 hours, thereafter at a temperature of 70 to 100 degree C. for 2.5 to 3.5 hours, and thereafter at a temperature of 100 to 130 degree C. for 14 to 18 hours;

b) then etching said aluminum foil in a desired pattern to make a planar resistance heating element; and

c) then printing carbon paste and connecting input terminals in parallel to said heating element.

2. The manufacturing method of claim 1, wherein the tempered aluminum foil is cleaned using a cleansing solution of pH 10 to 12, and dried at a temperature of 50 to 65°

C.